Asian Journal of Convergence in Technology
Issn No.:2350-1146, I.F-2.71
Study and Design of Agitators
Ajinkya A. Bapat
Department of Mechanical Engineering,
Finolex academy of management and technology,
Ratnagiri-415639,Maharashtra,india
ajinkyabapat@gmail.com
Abstract - Various engineering applications need devices that
satisfy diverse design requirements. This has always motivated
researchers towards development of devices that possess unusual
combination of properties. Mixing is a very important unit
operation in any chemical process industry. Certain processing
operations such as blending, dissolution, gas absorption,
crystallization, etc. need agitation of the liquids. In such
operations agitator system has to be provided along with basic
equipment. Design is crucial part comes along with any operation
requirement. The agitators are designed using fine quality
components with the help of sophisticated technology under the
strict supervision. These agitators are machines that are used in
industries to process products in the food, pharmaceutical,
chemical, and cosmetic industries for mixing liquids together.
Pharmaceutical preparations for treatment of conditions such as
rashes, skin irritation, Stings, fungal infections etc. are normally
supplied in the form of a cream or ointment as this provides an
effective means of delivering the active ingredient directly to the
required area.
Products can be either a water in oil (w/o) or oil in water (o/w)
emulsion, consisting of waxes, Emollients and lubricants
dispersed in an oil phase, and a water phase containing
emulsifying, Stabilizing and thickening agents, preservatives and
in some cases, colorant.
Keywords: mixing, design of agitator.
I. INTRODUCTION
Many operations depend to a great extent on effective
mixing of fluids. Dispersion characteristics can be considered
as the mixing of two or more immiscible liquids, solids and
liquids, or liquids and gases, into a pseudo-homogeneous
mass. Small drops are created to provide contact between
immiscible liquids. These liquids are mixed for specific
purposes, namely solvent extraction, removal or addition of
heat, and to affect mass transfer rates in reactors. Mixing is an
integral part of chemical industry. Agitation refers to the
induced motion of a material in a specified way, usually in
circular pattern inside some sort of container. Mixing is the
random distribution, into and through one another, of two or
more initially separate phases
The agitators are designed using fine quality components
with the help of sophisticated technology under the strict
supervision. These agitators are machines that are used in
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Dr. S S Goilkar
Principal,
Finolex academy of management and technology,
Ratnagiri-415639,Maharashtra,india
ssgoilkar@gmail.com
industries to process products in the food, pharmaceutical,
chemical, and cosmetic industries for mixing liquids together.
The choice of the agitator depends on the phase that needs
to be mixed (one or several phases): Liquids only, liquid and
solid, liquid and gas or liquid with solids and gas. Depending
on the type of phase and viscosity of the bulk, the agitator can
be named mixer, kneader, and dough mixer, amongst others.
The agitators use in liquids can be placed on the top of the
tank on vertical position, or horizontally (on the side of the
tank) or less common, agitator is located on the bottom of the
tankDry materials are charged through the top and ingredients
may be added as desired without interrupting mixing cycle.
Arrangements are available for injecting liquid or paste
additives into the mix through the top or bottom of the tank.
The screw's spiral action is upward, lifting ingredients from
the bottom of the tank up through those at the top. Discharge
is at the bottom and it fast and easy.
Pet foods, Spices, Textile softeners, Toothpastes are
generally made using vertical screw mixer. Dry materials are
charged through the top and ingredients may be added as
desired without interrupting mixing cycle. Arrangements are
available for injecting liquid or paste additives into the mix
through the top or bottom of the tank. The screw's spiral action
is upward, lifting ingredients from the bottom of the tank up
through those at the top. Discharge is at the bottom and it fast
and easy. The gentle blending action of the slow turning
blending screw is far gentler than that of a horizontal blender.
The blending screw orbits the conical vessel wall while it
turns and gently lifts material upward. The materials are then
thrust at the upper most batch level towards the centre of the
vessel, and then move slowly back down the centre, while
mixing with materials being moved upward by the orbiting
screw.
II. CONSTRUCTION AND WORKING
The spatial agitator consists of basic mechanism that
produces an oscillating motion from continuously rotary input.
The mechanism as shown in the figure is developed to
produce an oscillating motion in the vertically suspended
output shaft trough the continuously rotating horizontal input
shaft’. The input shaft carries an input crank that engages with
input shaft at one end and the fork at other. The fork is
coupled to output shaft by means of fork pin. During 0 to 180
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Asian Journal of Convergence in Technology
Issn No.:2350-1146, I.F-2.71
degree rotation f the input shaft the crank and the fork together
make output shaft to rotate in clockwise direction by 60
degrees, whereas during 180 to 360 degrees of input the output
changes direction and returns to mean position. The motor is
bolted to the base plate mounted on the base frame
Fig. 1 General design of agitator
III. DESIGN
In agitation mostly cylindrical vessel with a vertical axis is
used. The tank bottom is dished end. To eliminate sharp
corners or regions into which fluid currents would not
penetrate and also to withstand internal and external pressure
viz, vacuum. Liquid depth is approximately equal to the
diameter of the tank. An impeller is mounted on shaft, that is,
a shaft is supported from above. The shaft is driven by a
motor, sometimes, directly connected to the shaft but more
often connected to it through a speed-reducing gearbox.
Accessories such as inlet and outlet lines, heating and cooling
coils, jackets, and wells for thermometers or other temperature
measuring devices are usually included. Baffles are usually
included to prevent vortex formation.
In many solids-suspension tasks, especially in the
minerals-processing industries, abrasion can be a significant
issue. In this case, lower velocities may be required to limit
abrasion. An increased impeller size can compensate for the
lower velocities.
During power failures, sediments can quickly build up in
suspension tanks. Impellers are often designed to withstand
attempted restarts, while submerged in densely settled slurry.
In some instances, “restart in slurry” becomes the key design
criterion.
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Solids suspension and gas dispersion commonly occur
simultaneously in the chemical- and minerals-processing
industries. The presence of gas affects the performance of the
impeller and the ability of the fluid to suspend solids.
Likewise, the presence of solids affects gas dispersion. Both
must be taken under consideration
In this work the plan is to carry out the analysis of
cosmetic cream multiple impeller mixers and to find out basic
design considerations. In addition to agitator parameters and
the vessel geometry, the properties of both the liquid and the
solid particles influence the fluid-particle hydrodynamics and,
thus, the suspension. The important physical properties for
agitator design are: the liquid density, the density difference
between solids and liquid, the liquid viscosity, the average
particle size and the volumetric concentration of the solids are
needed. In addition to agitator design and power requirements,
which are fundamental to mixing systems, many other
considerations also play a parting maximizing performance.
These considerations include mechanical aspects, seal
selection, materials of construction and surface finishes
preventing fouling or aiding cleaning.
The design consists of major four factors. Identification of
the type of mixing to perform, inventory of the characteristics
of mixing materials, Identification of the global characteristics
of mixing rotors, choice of the rotors, calculation of the
various mixing parameters.
All mixing impellers produce both fluid velocity and fluid
shear, but different types of impellers produce different
degrees of flow and turbulence, either of which may be
important, depending on the application
- Food & Beverage & Dairy
- Pharmaceuticals
- Chemicals
- BioPharma
- Water treatment
The spatial agitator consists of an basic mechanism that
produces an oscillating motion from continuously rotary input.
The mechanism as shown in the figure is developed to
produce an oscillating motion in the vertically suspended
output shaft trough the continuously rotating horizontal input
shaft. The input shaft carries an input crank that engages with
input shaft at one end and the fork at other.
In system design we mainly concentrated on the following
parameters:
A. System Selection Based on Physical Constraints
While selecting any machine it must be checked whether it is
going to be used in a large scale industry or a small scale
industry. In our case it is to be used by a small scale industry.
So space is a major constrain. The system is to be very
compact so that it can be adjusted to corner of a room. The
mechanical design has direct norms with the system design.
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Asian Journal of Convergence in Technology Volume II, Issue III
Issn No.:2350-1146, I.F-2.71
Hence the foremost job is to control the physical parameters, Examples and industrial applications of agitation and mixing
so that the distinctions obtained after mechanical design can Process:
be well fitted into that  Blending of two mixable liquids like alcohols and
water / any solvent
B. Arrangement of Various Components  Dissolving solids into liquids like salts and water
Keeping into view the space restrictions the components  Liquid to liquid dispersion like dispersion of
should be laid such that their easy removal or servicing is pigments in suitable vehicles
possible. More over every component should be easily seen  agitation of the fluid to increase heat transfer between
none should be hidden. Every possible space is utilized in the fluid and a coil or jacket in the vessel wall
component arrangements.  Suspending of fine solid particles in a liquid like
suspending fine color powders in vehicles in oil
paints etc.
C. Components of System
As already stated the system should be compact enough so
that it can be accommodated at a corner of a room. All the
moving parts should be well closed & compact. A compact I. Basic design process is as follows
system design gives a high weighted structure which is
desired.
D. Man Machine Interaction
The friendliness of a machine with the operator that is
operating is an important criterion of design. It is the
application of anatomical & psychological principles to solve
problems arising from Man Machine relationship.
E. Servicing Facility
The layout of components should be such that easy servicing
is possible. Especially those components which require
frequents servicing can be easily disassembled.
F. Scope of Future Improvement
Arrangement should be provided to expand the scope of work
in future. Such as to convert the machine motor operated; the
system can be easily configured to required one. The die &
punch can be changed if required for other shapes of notches
etc.
G. Height of Machine from Ground
For ease and comfort of operator the height of machine should
be properly decided so that he may not get tired during
operation. The machine should be slightly higher than the
waist level, also enough clearance should be provided from
the ground for cleaning purpose.
H. Weight of Machine
The total weight depends upon the selection of material
components as well as the dimension of components. A higher
weighted machine is difficult in transportation & in case of
major breakdown; it is difficult to take it to workshop because
of more weight

For more effective homogenization it is needed to rigorously

shake and create turbulence in the contents. The process is
called as agitation. Purpose of agitation is intensification of
transport processes in agitated batch in case of heat and mass
Fig. 2 Generalized Design Steps
transfers oriented processes and preparation of materials of
required properties like suspensions, emulsion etc. in process
industries.
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Asian Journal of Convergence in Technology
Issn No.:2350-1146, I.F-2.71
1. Input data collection-
The basic step consists of collection of data regarding
industrial operating parameters. It depends upon type of
components to be mixed.
2. Analysis of mixing task-
There are many ways with the different components can be
mixed. E.g. liquid-liquid mixing, solid-liquid mixing, solid-
solid mixing.
3. Vessel dimension-
It can be determined using size of pressure vessel. It is
generally obtained by different standard codes.
4. Design process-
This consists of sizing of different components of agitator
using industrial parameters like pressure vessel design,
different impellers, vessel closure, supporting legs, motor to
run an agitator, supporting legs.
5. 2D and 3D drawing
Component drawings are obtained using different CAD
software’s. For reading 2D drawings are used and for
production purpose 3D drawings are used. These are generally
used for further for analysis software’s as input.
6. Stress analysis
When design process is finished last step remains, analysis.
Validation is very important step to follow. When drawings
are made, these are imported to analysis software’s. The
analysis is made and conclusion is drawn. If no errors are
found then design is finalised. If results have errors then
design is iterated and revised design is again analysed till final
solution is obtained.
IV. CONCLUSIONS
Process equipment design is nowadays very essential part
of industry. Each component comes with variety of
application. Many chemical plants are now modified and
expanded both technically and economically. So design of
these elements must be very efficient and economic. Agitator
is used in variety of applications in chemical industry.
Because of its diversity, the finite element method is
numerical analysis technique for obtaining approximate
solutions to a wide variety of engineering problems.
Flexibility as an analysis tool, it is receiving much attention in
almost every industry. It is not possible to obtain analytical
mathematical solutions for many engineering problems. The
finite element method has become a powerful tool for the
numerical solutions of a wide range of engineering problems.
It has been developed simultaneously with the increasing use
of the high-speed electronic digital computers and with the
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Special issues in Mechanical Engineering
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growing emphasis on numerical methods for engineering
analysis.
To validate the results it is necessary to carry out
analytical procedure using experimental results. It is
appropriate to do this in steps. The process is at first only
investigated partially, both in the experiment and in the
analytical calculation.
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